Presentation Transcript

1. Examining The Battery Quality and Standards for LEVs in Asia

   Vivian Wei General Manager, China Operations eCycleElectric Professional LEV Consulting Mar. 2012
2. eCycleElectricConsultingA Passionate, Experienced Team To Assist You Every Step of the Way 42 years of experience in the bike industry 16 years of experience in the e-bike industry 77 satisfied clients in 12 countries and regions 20+ years of experience in the motor business 40+ media contacts in the EV and LEV world 6,000+ contacts in the LEV industry worldwide Offices in USA, China, Taiwan and Germany
3. Light Electric Vehicle Association Founded in 2009 and based in the US, LEVA today has over 200 members from 25 countries, over 40 global media partners and over 6000 industry contacts. The Light Electric Vehicle Association (LEVA) represents the strategic interests of light electric vehicle retailers, dealers, distributors, manufacturers and suppliers to promote the development, sale, and use of LEVs worldwide. Members receive support and educational resources to expand their businesses while initiating efforts to influence and adopt legislation, regulation, performance standards and general best practices in the light electric vehicle industry.
4. Outline LEV Battery Industry in China Battery Supplier Qualifications Definition of Quality in Different Markets Comparison of Different Battery Types Battery Manufacturer’s Perspective Examine and Control Cell Quality Examine and Control Battery Pack Quality LEV Specific Battery Testing LEV Manufacturer’s Perspective LEV Prototype Development Stage LEV Production Stage
5. LEV Battery Industry in China +29 million e-bikes produced in 2011 +0.5 million e-bikes exported in 2011 +600 lead-acid battery manufacturers in 2012 (down from +3,000 in 2011) +60 lithium battery manufacturers in 2012
6. Labor Intensive VS Fully Automatic
7. Labor Intensive VS Fully Automatic
8. Manufacturing Dust Control
9. Quality Inspection Stations
10. Warranty+ Certificate ≠ Quality
11. Battery Supplier Qualifications Willingness to customize a function specific pack After-sales responsibility and commitment Management with battery expertise Strong R&D and engineering capability Required certifications and Insurance
12. How to Define Quality in Different Markets Performance Climate Terrain Road Conditions Purpose of Use Warranty Cycle Life Calendar Life Intelligence Safety Reliability
13. Different Markets Needs for Battery
14. Different Purposes of Use Commuting Shopping
15. Different Purposes of Use Picking up Kids Postal Services
16. Different Purposes of Use Food Delivery Recreation
17. Lead Acid Battery Module Characteristics
18. Characteristics of Lithium-Ion Modules
19. Comparison of Different Battery Types
20. How to Realize Quality Require the extreme requirements and expectations of all the markets and make that your requirement. Build performance requirements into vendor requirements and testing protocol.
21. Examine and Control Cell Quality Raw Materials Components Assembly Equipment Assembly Process Testing Facility Testing Protocol
22. Examine and Control Cell Quality Humidity and Dust control will affect the self-discharge rate of the cells and ultimately the consistency of the cells.
23. Examine and Control Pack Quality---Cell Consistency High-precision cell test equipments are needed to accurately test and group the cell voltage and resistance before pack assembly to ensure the consistency of cells. Match detector for cells HIOKIhigh-precision voltage resistance test machine High precision, multi-function electrical performance test machine
24. Examine and Control Pack Quality--BMS Test To ensure the quality of BMS, each BMS has to be tested for all the performances. A BMStest system is needed to test the whole BMS function pre-assembly or post-assembly. BMSTest Items： over charge protection; over discharge protection; over current protection; short-circuit protection; BMScurrent consumption test; BMStemperature protection test Power Battery Testing System
25. LEV Specific Battery Test LEVperformance test of complete bike Arbinhigh power charge/discharge test machine thermal shock test machine Vibration test machine
26. Performance Test Compatibility TestTest the matching of packs, accessory products and chargers. Test Machine: Product and Charger Voltage, Internal Resistance TestTest the open-circuit volts, AC resistanceTest Machine: Resistance/Voltage meter Rated CapacityTest the capacity when charge at 0.2C and discharge at 0.5CTest Machine: Discharge tester Electricity Maintain and RecoveryCharge at 0.2C and store for 30 days, test the capacity; recharge, test capacity recovery.Test Machine: Discharge tester Cycle TestCharge and discharge the pack test the capacity after cycleTest Machine: Discharge tester Battery IndicatorTest indicator condition at different electricity stateTest Machine: Multi function meter
27. Environment Test Temperature ShockPut the pack in mutual exchange of high and low temperature, test the performance changeTest Machine: Thermal Shock Chamber VibrationVibrate the packs and test the performance changeTest Machine: Vibration platform, discharge tester High/Low Temperature CapacityTest the pack capacity at high and low temperatureTest Machine: Thermal Shock Chamber, charge/discharge tester
28. Safety Test High current discharge capacityDischarge the full-charged pack with high current and test the capacityTest Machine: Discharge tester Over charge/discharge protectionTest the over charge/discharge protection voltageTest Machine: Discharge tester Over current protectionTest the over protection currentTest Machine: Discharge tester Pulse dischargePulse discharge the pack with different currents, test the pack performanceTest Machine: Discharge tester Short-circuit protectionShort-circuit the pack and test if the pack has protectionTest Machine: Short-circuit platform
29. Drive System Integration
30. Battery Testing-LEV Prototype Development Work with the supplier to develop a prototype pack for evaluation purposes. Conduct both bench (load and cycle testing) on the preliminary prototype and real world ride testing to flesh out any issues. Go back and forth a few times before getting it right. Send the complete pack to a third party test lab to do destructive testing to uncover any possible safety issues. Conduct a small pilot production, and go through the testing steps once more. Move to mass production and the IQC process if all of the pilot packs pass testing.
31. DAS-Data Acquisition System DAS is used conduct performance tests in real life rides, as well as test stand rides. Depending on the test results, battery parameters and controller parameters are adjusted accordingly. E-bike Performance Test Current Voltage Range Temperature Speed Battery Capacity
32. Battery Testing-LEV Production LEV manufacturers often work with their battery suppliers on a testing protocol of production battery packs for incoming quality control purposes.  Supplier Test Random Inspection Full Inspection Sampling on the complete bike Test Ride
33. Supplier Test Batteries are required to be 100% tested at supplier’s end with the submission of a test report.
34. Random Inspection Physical Appearance Accuracy of Customer Logo Physical and Technical Specs Charger Performance Max Charging Voltage Discharging Capacity Test Cut-off Discharge Voltage
35. Full Inspection After random inspection, 100% inspection will be conducted on Physical Appearance Accuracy of Customer Logo Charging Port Discharging Port Battery Voltage Inspection Logo Size and Location Inspection Battery Capacity Inspection
36. Sampling on the complete bike Depending on the production model lot size, every 20 to 50 bikes, one bike will be randomly selected for its complete performance charge / discharge test to ensure under load the bike performance, battery performance, and charge / discharge characteristics meet the standards set for the particular model.
37. Test Ride To ensure the battery performs properly on the bike, every battery will be installed on the bike for a test ride. During the ride, the actual bike functions are switched to test for performance consistency.
38. Our Most Rewarding Moment
39. Special Thanks To: Tianjin Lishen Battery Joint-Stock Co. Ltd. Currie Technologies Fairly Bike Manufacturing Company, Ltd. Tianjin Flying Pigeon Electric Bicycle Manufacture Co., Ltd.
40. Thank You! For any questions, please contact Vivian Wei at vivian@ecycleelectric.com